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Supported metal single atom catalysts (SACs) present an emerging class of low-temperature catalysts with high reactivity and selectivity, which, however, face challenges on both durability and practicality. Herein, we report a single-atom Pt catalyst that is strongly anchored on a robust nanowire forest of mesoporous rutile titania grown on the channeled walls of full-size cordierite honeycombs. This Pt SAC exhibits remarkable activity for oxidation of CO and hydrocarbons with 90% conversion at temperatures as low as ~160 o C under simulated diesel exhaust conditions while using 5 times less Pt-group metals than a commercial oxidation catalyst. Such an excellent low-temperature performance is sustained over hydrothermal aging and sulfation as a result of highly dispersed and isolated active single Pt ions bonded at the Ti vacancy sites with 5 or 6 oxygen ions on titania nanowire surfaces. Supported metal single-atom catalysts face challenges on both durability and practicality. Here, the authors demonstrate that a sustained 90% diesel oxidation conversion at ~160 o C is achieved by single-atom Pt on TiO 2 nanowire-array integrated catalytic converter.

Introducing transition-metal components to ceria (CeO2) is important to tailor the surface redox properties for a broad scope of applications. The emergence of high-entropy oxides (HEOs) has brought transformative opportunities for oxygen defect engineering in ceria yet has been hindered by the difficulty in controllably introducing transition metals to the bulk lattice of ceria. Here, we report the fabrication of ceria-based nanocrystals with surface-confined atomic HEO layers for enhanced catalysis. The increased covalency of the transition-metal–oxygen bonds at the HEO–CeO2 interface promotes the formation of surface oxygen vacancies, enabling efficient oxygen activation and replenishment for enhanced CO oxidation capabilities. Understanding the structural heterogeneity involving bulk and surface oxygen defects in nanostructured HEOs provides useful insights into rational design of atomically precise metal oxides, whose increased compositional and structural complexities give rise to expanded functionalities.

An industry-defined evaluation protocol was used to evaluate the hydrocarbon trapping (HCT) and passive NOx adsorption (PNA) potential for BEA, ZSM-5, and SSZ-13 zeolites with ion-exchanged Pd or Ag. All materials underwent 700 °C degreening prior to exposure to an industry-derived protocol gas stream, which included NOx, ethylene, toluene, and decane as measured trapping species as well as common exhaust gasses CO, H2O, O2, CO2, and H2. Evaluation showed that BEA and ZSM-5 zeolites were effective at trapping hydrocarbons (HCs), as saturation was not achieved after 30 min of exposure. SSZ-13 also stored HCs but was only able to adsorb 20–25% compared to BEA and ZSM-5. The presence of Ag or Pd did not impact the overall HC uptake, particularly in the first three minutes. Pd/zeolites had significantly lower THC release temperature, and it aided in the conversion of the released HCs; Ag only had a moderate effect in both areas. With respect to NOx adsorption, the level of uptake was much lower than HCs on all samples, and Ag or Pd was necessary with Pd being notably more effective. Additionally, only Pd/ZSM-5 and Pd/SSZ-13 continue to store a portion of the NOx above 200 °C, which is critical for downstream selective catalytic NOx reduction (SCR). Hydrothermal aging (800 °C for 50 h) of a subset of the samples were performed: BEA, Pd/BEA, ZSM-5, Pd/ZSM-5, and Pd/SSZ-13. There was a minimal effect on the HC storage, ~10% reduction in capacity with no effect on release temperature; however, only Pd/SSZ-13 showed significant NOx storage after aging.

This review article focuses on the latest advances in the synthesis of inorganic nano-catalysts using microwave heating, which has progressed significantly since its initial implementation in the mid-1980s. Over the years, nanoparticles (NPs), which inherently offer better surface accessibility for heterogeneous catalysis, have been synthesized using a wide array of heating methods. Microwave heating is one such method and employs a unique heating mechanism that can have several benefits for catalysis. When compared to conventional form of heating which relies on inter-layer mixing via convection, microwave heating operates through the chemical polarity in the target chemicals leading to an “inside-out” mode of heating. This heating mechanism is more targeted and therefore results in rapid synthesis of catalytically active NPs. Platinum group metals (PGM) have classically been the focus of nano-catalysis; however, recent efforts have also applied non-PGM group metals with the goals of lower costs, and ideally, improved catalytic reactivity and durability. This is especially of interest with respect to Pd because of its current historically high cost. Investigations into these new materials have primarily focused on new/improved synthetic methods and catalytic compositions, but it is important to note that these approaches must also be economic and scalable to attain practical relevance. With this overarching goal in mind, this review summarizes notable recent findings with a focus on Pd-dilution and microwave heating in a chronological fashion.

With emission control regulations getting stricter, multi-functional catalyst systems are increasingly important for low-temperature operation. We investigate a wide range of multi-component catalyst systems, as physical mixtures and in multi-bed configurations, while varying the ratios of hydrocarbon traps (HCT), passive NOx adsorbers (PNAs), and diesel oxidation catalysts (DOC). Using industrially guided protocols, we measured the ability of these complex catalyst systems to reduce emissions during a 40 °C/min temperature ramp to simulate cold-start conditions. Using a temperature boundary condition of 250 °C, the average conversion was calculated for each regulated pollutant: CO, NOx, and total hydrocarbons (THC). An emissions merit function was developed to evaluate the effectiveness of each system relative to the relevant emission standards and expected engine exhaust concentrations. This merit function identified that a 1:1:4 ratio of PNA:HCT:DOC was the most effective emissions reduction configuration and had similar reactivity as a physical mixture or as a PNA→HCT→DOC multi-bed reactor.

With increasing concerns about global warming, the push for sustainable and eco-friendly fuels is accelerating. Propane, recognized as liquefied petroleum gas or LPG, has garnered research interest as an alternative fuel due to its notable advantages, including a high-octane rating, reduced greenhouse gas emissions, and potential cost-effectiveness. However, to realize its full potential as an alternative fuel it is essential to develop catalysts that efficiently handle emissions at low temperatures. In our research, we investigated three distinct palladium (Pd)-based three-way catalyst (TWC) formulations (PdRh, Pd-only, and Pd-OSC) to investigate the influence of typical TWC components rhodium (Rh) and oxygen storage components (OSC) in exhaust scenarios relevant to propane-fueled engines. Among these, the formulation containing oxygen storage components (Pd-OSC) showed the highest reactivity for both NO and C3H8 while minimizing performance degradation from hydrothermal aging (HTA). Notably, the temperature of 50% conversion (T50) for propane in the Pd-OSC fresh and HTA sample was lower by 30 °C and 13 °C, respectively, compared to the Pd-only sample, highlighting the role of oxygen storage materials in enhancing catalyst performance, even without dithering. Additionally, N2 physisorption showed that the Pd-OSC sample has a higher surface area and increased pore volume. This underscores the idea that OSC materials not only augment the catalyst’s porosity but also optimize reactant accessibility to active sites, thus elevating catalytic efficiency. In addition to evaluating performance, we further explored the performance and characteristics of the catalysts using catalytic probe reactions, such as water–gas shift and steam reforming reactions.

Palladium(II) oxide/γ-alumina (PdO/γ-Al 2 O 3 ) catalysts are one of the most active catalytic components for the complete oxidation of methane. Under reaction conditions, especially in a wet feed, the catalysts suffer severe performance degradation. This study establishes a series of testing protocols to systematically investigate the causes of catalyst deactivation under methane oxidation reaction conditions. Four distinct catalyst deactivation modes are identified. Two of the deactivation modes are directly related to water, either from the feed gas or as a part of the reaction products, with one (Mode 2) being attributed to the formation of surface hydroxyl groups and the other (Mode 3) to the competitive adsorption of water on the catalysts. The impact of the two deactivation modes is acute and severe but reversible. In contrast, the other two deactivation modes are gradual and persistent but irreversible. Both modes are induced by methane oxidation reaction, with the impact of a wet feed (Mode 4) being substantially more severe than that of a dry feed (Mode 1). The major cause of the irreversible catalyst deactivation is attributed to surface reconstruction of palladium(II) oxide nanoparticles, which behaves as a passivation layer lowering the number of coordinately unsaturated palladium sites for methane activation. Although the passivation layer is relatively stable against thermal or hydrothermal treatment, it is not completely inert. Formation and partial regeneration of the passivation layer is a highly dynamic process and heavily depends on the reaction temperature: a lower reaction temperature (≤450°C) can lead to quicker catalyst deactivation; but a higher reaction temperature (between 500–550°C) can result in a greater extent of catalyst deactivation.

In the present study, two industry primary and secondary zinc dialkyldithiophosphate standards, ZDDP1 and ZDDP2, respectively, are evaluated for their impact on the performance of Pd-based three-way catalyst and bench-marked against two mixed lubricant additives formed from either ZDDP1 or ZDDP2 with a second-generation oil-miscible phosphoric-containing ionic liquid (IL). The three-way catalysts (TWCs) are exposed to the lubricant additives in an engine bench under four different scenarios: a base case with no additive (NA), ZDDP1, IL+ZDDP1, ZDDP2, and IL+ZDDP2. The engine-aged TWC samples are characterized through a variety of analytical techniques, including evaluation of catalyst reactivity in a bench-flow reactor. With respect to the water–gas shift reaction and the oxygen storage capacity, the ZDDP2- and IL+ZDDP2-aged TWC samples are more degraded than the ZDDP1- and IL+ZDDP1-aged TWC samples. X-ray diffraction (XRD) patterns indicate that phosphorus in the form of CePO4 was found to be present in the washcoat of all TWC samples, with the highest amount found in the ZDDP2-aged TWC sample. The results obtained from XRD are further confirmed by those from inductively coupled plasma-optical emission spectroscopy (ICP-OES), which show that more phosphorus is detected in the washcoat of ZDDP2- and IL+ZDDP2-aged TWC samples than in the ZDDP1- and IL+ZDDP1-aged TWC samples.

A PtPd/Al2O3 catalyst developed for the complete oxidation of methane from the ventilation air of underground coal mines is compared against a model PdO/Al2O3 catalyst. Although the PtPd/Al2O3 catalyst is substantially more active and stable than the model catalyst, the nature of active sites between the two catalysts is deemed to be fundamentally the same based on their response to different feed gas compositions and the evolution of surface CO adsorption complexes during time-resolved CO adsorption DRIFTS experiment. For both catalysts, coordinatively unsaturated Pd sites are considered the active centers for methane activation and the subsequent oxidation reaction. H2O competes with CH4 for the same active sites, resulting in severe inhibition. Additionally, the CH4 oxidation reaction also causes self-inhibition. Taking both inhibition effects into consideration, a relatively simple kinetic model is developed. The model provides a good fit of the 72 sets of kinetic data collected on the PtPd/Al2O3 catalyst under practically relevant reaction conditions with CH4 concentration in the range of 0.05–0.4%, H2O concentration of 1.0–5.0%, and reaction temperatures of 450–700 °C. Kinetic parameters based on the model suggest that the CH4 activation energy on the PtPd/Al2O3 catalyst is 96.7 kJ/mol, and the H2O adsorption energy is −31.0 kJ/mol. Both values are consistent with the parameters reported in the literature. The model can be used to develop catalyst sizing guidelines and be incorporated into the control algorithm of the catalytic system.

In this study the effect of ceria addition on the performance of a model Ba-based lean NOx trap (LNT) catalyst was examined. The presence of ceria improved NOx storage capacity in the temperature range 200–400 °C under both continuous lean and lean-rich cycling conditions. Temperature-programmed experiments showed that NOx stored in the ceria-containing catalyst was thermally less stable and more reactive to reduction with both H2 and CO as reductants, albeit at the expense of additional reductant consumed by reduction of the ceria. These findings demonstrate that the incorporation of ceria in LNTs not only improves NOx storage efficiency but also positively impacts LNT regeneration behavior.